Encapsulated flexible hinges

Abstract

The present invention provides an encapsulated flexible hinge that is particularly suited for use as an original part or as a replacement hinge on a cooler. The encapsulated flexible hinge is comprised of a flexible woven central reinforcement member having a rubber or polymer coating that has been forced through the reinforcement member to create an outer and an inner rubber coating that encapsulates the reinforcement member. In another embodiment, the inner and outer coating is comprised of the same or two different materials that are vulcanized together after being extruded on either side of the reinforcement member. The encapsulated flexible hinge may take on various shapes, and can be cut into a specific shape if need be.

Claims

1. An encapsulated flexible hinge comprising: a fibrous reinforcement member having a front side and back side, said fibrous reinforcement member formed from a plurality of threads interlaced with respect to each other, said fibrous reinforcement member cut into a polygonal shape having a plurality of edges, a front surface and a back surface, a plurality of apertures extending through said fibrous reinforcement member, said front surface and said back surface; a polymer coating encapsulating said plurality of threads, forming said reinforcement member, said polymer coating is extruded through the reinforcement member to encapsulate said plurality of threads, forming said encapsulated flexible hinge; said plurality of apertures positioned to allow said encapsulated flexible hinge to be attached to a fixed member and a moveable member with fasteners, said encapsulated flexible hinge spanning a gap between said fixed member and said moveable member to allow said moveable member to pivot a limited amount about an axis created by said encapsulated flexible hinge.

2. The encapsulated flexible hinge of claim 1 wherein said polymer is rubber.

3. The encapsulated flexible hinge of claim 2 wherein said rubber is a nitrile rubber.

4. The encapsulated flexible hinge of claim 1 wherein said fibrous reinforcement member is constructed from polyester fibers.

5. The encapsulated flexible hinge of claim 1 wherein said fibrous reinforcement member is constructed from nylon fibers.

6. The encapsulated flexible hinge of claim 1 wherein said fibrous reinforcement member is constructed from polyester and nylon fibers woven into a cross pattern.

7. The encapsulated flexible hinge of claim 1 wherein said fibrous reinforcement member is constructed from polyester and nylon fibers knit into interlocked loops, forming a pattern.

8. The encapsulated flexible hinge of claim 3 wherein said nitrile rubber is extruded along both sides of said fibrous reinforcement member and vulcanized at least once to insure that the nitrile is bonded in and around said fibrous reinforcement member.

9. The encapsulated flexible hinge of claim 6 wherein said nylon fibers are oriented in the longitudinal direction of encapsulated flexible hinge, while said polyester fibers are oriented perpendicular with respect to said nylon fibers.

10. The encapsulated flexible hinge of claim 1 wherein said encapsulated flexible hinge is constructed from fire hose.

11. The encapsulated flexible hinge of claim 1 wherein said encapsulated flexible hinge is rectangular in perimeter shape.

12. The encapsulated flexible hinge of claim 1 wherein said encapsulated flexible hinge is utilized as a latch, said latch being secured along one edge while a second edge is free to flex by hand, whereby said second edge may be flexed so that a latch aperture extends over a pin member to function to secure said pivotable member.

13. The encapsulated flexible hinge of claim 1 wherein said encapsulated flexible hinge is provided as a kit, said kit including at least one said encapsulated flexible hinge and a plurality of fasteners.

14. The encapsulated flexible hinge of claim 13 wherein said kit includes at least two said encapsulated flexible hinges.

15. The encapsulated flexible hinge of claim 13 wherein said fasteners are screws.

16. The encapsulated flexible hinge of claim 13 wherein said fasteners are rivets.

17. An encapsulated flexible hinge comprising: a fibrous reinforcement member having a front side and back side, said fibrous reinforcement member formed from a plurality of polyester and nylon fibers woven into a cross pattern with respect to each other, said fibrous reinforcement member cut into a polygonal shape having a plurality of edges, a front surface and a back surface, a plurality of apertures extending through said woven reinforcement member, said front surface and said back surface; a polymer coating extruded through said reinforcement member encapsulating said polyester and nylon fibers, forming said reinforcement member, said polymer coating covering said front surface and said back surface, forming said encapsulated flexible hinge; said plurality of apertures positioned to allow said encapsulated flexible hinge to be attached to a fixed member and a moveable member with fasteners, said encapsulated flexible hinge spanning a gap between said fixed member and said moveable member to allow said moveable member to pivot a limited amount about an axis created by said encapsulated flexible hinge.

18. The encapsulated flexible hinge of claim 17 wherein said polymer coating is a nitrile rubber.

19. The encapsulated flexible hinge of claim 18 wherein said encapsulated flexible hinge is provided as a kit, said kit including at least one said encapsulated flexible hinge and a plurality of fasteners.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) FIG. 1 is a rear view of a cooler including the encapsulated flexible hinge;

(2) FIG. 2 is an isometric view, partially in section, of one embodiment of the encapsulated flexible hinge;

(3) FIG. 3 is an isometric view of a cooler latch constructed from the encapsulated reinforcement member material; and

(4) FIG. 4 is a front view of the cooler including the latch constructed from the encapsulated reinforcement member material.

DETAILED DESCRIPTION OF THE INVENTION

(5) While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred, albeit not limiting, embodiment with the understanding that the present disclosure is to be considered an exemplification of the present invention and is not intended to limit the invention to the specific embodiments illustrated.

(6) Referring now to FIGS. 1-3, the present invention relates to an encapsulated flexible hinge 1 for use as a hinge between the lid 20 and box 30 of a cooler 2. The encapsulated flexible hinge 1 is comprised of a woven reinforcement member 22 having a front side 10 and back side 12 of a rubber or flexible type polymer extruded through the reinforcement member to encapsulate the fibers of the reinforcement member 22. In a preferred embodiment, the reinforcement member is constructed from polyester 24 and nylon fibers 26 woven into a cross pattern and encapsulated in nitrile rubber 28. The nitrile rubber may be either extruded through the polyester and nylon as a single piece or, alternatively, it may be extruded along both sides of the polyester/nylon and vulcanized once or twice to insure that the nitrile is bonded in and around the polyester/nylon fibers. In the preferred embodiment, the nylon fibers are oriented in the longitudinal direction of the hinge, while the polyester fibers are oriented perpendicular to the nylon fibers. This construction provides the most flexibility to the encapsulated flexible hinge 1 while providing the best stability to prevent side to side flexing of the hinge A top portion 14 and bottom portion 16 of the encapsulated flexible hinge 1 include apertures 18 that extend through the encapsulated flexible hinge 1 from the front side 10 to the back side 12. In one embodiment, the hinge may be constructed from a material such as used fire hose which has been opened into a flat position and die cut with a steel rule, standard dies or by hand. This allows recycling of materials and fast, precise manufacturing while still maintaining low tool cost. This construction also allows a variety of fiber materials to be substituted for the polyester/nylon combination without departing from the scope of the invention. It should also be noted that while the preferred embodiment is described as woven, non-woven, knits, knotted, braided, and stitch through, the construction also allows various polymers that are suitable for encapsulating the fibers to be substituted for the Nitrile without departing from the scope of the invention. The encapsulated construction allows the hinge 1 to get wet repeatedly without rotting or molding, and is resistant to the damaging effects of exposure to sunlight and chemicals. Additionally, the elastic construction provides flexibility and elasticity, which is imperative to operate a cooler top from the open to closed position repeatedly. Still, the polymeric coating provides protection against chafing to the reinforcement member 22, allowing long service life. Additionally, the flexible hinge 1 can take on various shapes, and can be cut into a specific shape if need be. Thus, the flexible replacement hinge 1 can be used with various types and models of coolers available on the market, making the encapsulated flexible hinge 1 universal to most any cooler. Still yet, the flexible construction eliminates the need for multiple adjacently positioned hinges to be axially aligned for proper operation, reducing manufacturing and assembly costs of cooler production.

(7) In at least one embodiment, the hinge may be supplied as a kit for replacing broken or pre-existing cooler hinges. In this embodiment, the hinges are supplied with fasteners, which may be screws, rivets or the like, for securing the encapsulated flexible hinge 1 to the box 30 and lid 20. The encapsulated flexible hinge 1 is used as a replacement by securing the hinge 1 to the cooler 2 using the fasteners, not shown. The fasteners secure the top portion 14 of the hinge 1 to the lid 20 using the provided apertures 18, while the bottom portion of the hinge 16 is secured to the box 30 using the provided apertures 18.

(8) Referring to FIGS. 3 and 4, an encapsulated flexible latch 100 is illustrated. The encapsulated flexible latch 100 is constructed from the same materials as the encapsulated flexible hinge 1 and operates in the same manner. The encapsulated flexible latch 100 is secured to the lid 20 of the cooler 2, and a pin member 32 or hook (not shown) is provided on the front portion of the box 30. Latch aperture 34 is provided to slip over the pin member 32 to hold the lid in a closed position. Release of the latch is accomplished by flexing the encapsulated flexible latch 100 sufficiently to allow the latch to be free from the pin, thereby allowing the lid to open as desired. Since the encapsulated flexible latch 100 is constructed from like materials as the flexible hinge, its construction provides the same advantages to the latch as are seen in the hinge. It should be noted that while the present device is described as being useful for coolers, it could also be used for applications such as, but not limited to, tackle boxes, tool boxes, deck boxes, and the like having hard component parts. It should be noted that while the preferred embodiment includes the reinforcement member, other embodiments may be constructed using only the vulcanized rubber or the two layers of rubber vulcanized together without departing from the scope of the invention.

(9) All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.

(10) It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention, and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.

(11) One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary, and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.